Isomerizing hydrocarbons



Patented July 28,1942

' 2,291,376 ISOMERIZING HYDROCARBONS Harry .No Drawing.

A. Cheney, Berkeley, Shell Development Company, CaliL, a corporation of Delaware Application April 8, 1941,

Calif., assignor to San Francisco,

Serial No. 387,463 14 Claims. (Cl. 260-676) The present invention relates to a new and improved method for the isomerization of saturated hydrocarbons, and more particularly saturated hydrocarbons containing from four to nine carbon atoms. the invention relates to an improved method whereby butane and/or pentane can be more efiiciently isomerized.

Saturated hydrocarbons .containing at least tical consideration and A particular embodiment of 5 four carbon atoms are capable of existing in isol0 meric modifications, the creases rapidly with the increase of the number of carbon atoms in the molecule. Notwithstanding the large number of isomeric forms possible, the hydrocarbons containing, for example, from four to nine carbon atoms in the molecule and available in natural sources such as petroleum and in certain distillate products of many ordinary refinery operations consist predomi nantly of the normal modification. The greater part of these hydrocarbons is used in fuels for internal combustion engines. chemical activities and the ignition characteristics of a large number of the possible isomers have shown that certain isomeric modifications are vastly superior to others and that, in general, .the naturally occurring normal isomers are often the least preferred. Normal pentane, for example, obtained in large quantities from petroleum, is chemically quite unreactive and in view of its poor ignition characteristics is a poor fuel component for internal combustion engines. Its isomer, isopentane, on the other hand, is far more reactive chemically and can/be alkylated readily with oleiinic duce saturated higher molecular weight hydrocarbons having excellent ignition characteristics. Isopentane is, of itself, an exceptionally valuable motor fuel component. In view of the vastly superior properties of the highly branched hydrocarbons over the normal or less branched hydrocarbons, a process enabling conversion of the normal or less branched hydrocarbons, available in large quantities, to their more highly branched forms isvery desirable. It is well known that isomerization of saturated hydrocarbons can be catalyzed by the aluminum halides. Normal butane, for example, is isomerized at room temperature in a period 0 about a month to an equilibrium mixture of normal butane andisobutane containing about 80% isobutane in the'presence of aluminum bromide or aluminum chloride. .It' is also known'that the presence of a hydrogen halide, such as hydrogen chloride, accelerates' the reaction, and it 55 peratures above hydrocarbons to 'pronumber of which in- Studies of the I the eflicient halide catalysts.

as an isomerization catalyst.

proved to be substantially was recently found that by the use of a large partial pressure of hydrogen chloride such isomeri'zation reactions may be made to approach a practical rate.

ever, per se, even in the presence of a hydrogen halide, are not entirely satisfactory catalysts for hydrocarbon isomerization. At low temperatures usually too slow for pracat higher temperatures cause degradation reactions which lead to the formation of by-products which, in turn, polymerize and undergo other secondary reactions. These by-products even when formed in relatively small amounts quickly coat the catalyst particles, preventing efficient contact, and cause the particles of aluminum hal-' ide to agglomerate into sticky lumps which slowly change to an oily liquid.- This oily liquid has a certain catalytic activity-and is capable of catalyzing polymerization and similar reactions but is much less active than the aluminum the isomerization rate is these catalysts tend to In view of these practical difiiculties, considerable work has been done in an effort to discover a better catalyst. It is known that a large number of metal halides suchas the halides of Be, B, Ti, V, Cr, Mn, Fe, Ni, Co, Zn, Bi, acids such as sulfuric acid,-sulfonio acids, phosphoric acids, and the like and even certain clays, etc., act similarly to aluminum halides in many reactions su h as the polymerization of olefines, alkylation of aromatic hydrocarbons, etc., andit was assumed that of these catalysts at least some would prove to be active isomerization catalysts; However, all of these materials inactive as isomerization catalysts. It is true that isomerization of certain saturated hydrocarbons to relatively small extents has been noted with such materials as zirconium chloride, beryllium chloride, molybdenum sulfide, and a mixture of boron fluoride and nickel under severe conditions, but processes utilizing these materials fail to attain yields and efliciency essential to practical com mercial operation. It is now well known that the efiectiveness of a catalyst in its application to other hydrocarbonreactions such as polymerization, alkylation, cracking, etc., is no criterion of its ability to catalyze the isomerization of saturated hydrocarbons.

I have investigated the use of liquid aluminum The aluminum halides per se when. used in the molten state are entirely unsuited as isomerization catalysts since at temtheir melting points they cause halides Zr, Sn, Sb.

26%, that ditions" are identical. It is almost complete degradation of the hydrocarbon. ,It is known that the aluminum halides react with .One of the sisting 01' tion of normal bu ane under'the following conditions: Temperature C 100 Contact time -minutes 30 Normal butane percent by weight of the total charge 55 Catalyst o 39 Hydrogen chloride do 6- The conversion, oi'n-butan'e to isobutane was the hydrocarbon product contained 26% isobutane.

promoted catalysts of saturated hydrocarbons may be considerably improved rates and excellent conversions obtained.

v may be effected with the superior liquid catalysts ina. commercially attractive and much more practical way.

The superior conversions obtainable using the case, aside from the catalyst employed, the conto be understood, therefore, that these examples are set forth to demonstrate the superiority of the process 01' my Example III I Normal butane was isomerized under the conditions described in the Example IV Normal butane was isomerized under the conditions described in ined were 36.3% and 58.8%, respectively.

Example V Normal 'butane ditions described promoted with 1% by weight oivanadium chlo-' I or normal butane to isobutane was 32.3%.

As will be seen from the above examples,

use of even' relatively smallamounts of promoters; the isomerization results in materially increasing carbon fractions the process of the invention,

moted catalysts of the above described type. In the catalysts employed in the process of ,my innormal butane and normal pentane contents of commercial hydrocarbon mixtures such as are obtained from natural gases, petroleum distillates, cracked distillates, etc. to their valuable branched chain isomers. Especially suitable mixtures of hydrocarbons are 'the so-called butane-butylene fractions. and pentane-amylene fractions from which unsaturated hydrocarbons have been substantially removed. Treatment'of such mixtures obtained, for instance, as by-products in the sulfuric acid alkylation of isoparafllns their contents of branched chain isomers and converting them to suitable raw materials for reuse in the algylation process. Technical butane and pentane fractions such as those containing from '10% to 98% of the normal isomer and from 2% to 30% of the branched chain isomer may be .conveniently treated in accordance withthe process of the invention and their content of branched chain isomers materially increased without loss due to decomposition, and side reactions. Other mixtures of saturated hydrocarbons such as straight run gasoline, casinghead gasoline, etc., containing appreciable quantities of normal butane, normal pentane, cyclohexane, methyl cyclohexane, or lower boiling nonbranched saturated hydrocarbons may be advantageously treated to produce products which are suitable for alkylation of olefins and have su-{ peri'or ignition characteristics. It is found that the greatest improvement in ignition characteristics is obtained when treating such hydroboiling predominantly below 70 C. x v

The hydrocarbon or mixture ofhydrocarbons treated is preferably substantially free of materials which are particularly prone to undergo side reactions such as degradation, polymerization, etc., under the reaction conditions. According to the preferred embodiment of the invention, excessive quantities of olefins, diolefins, orother detrimental impurities in the hydrocarbon or hydrocarbon mixture such as by a mineral acid tion, or the like. 1

The saturated hydrocarbon or mixture of saturated hydrocarbonsis isomerized, according to using molten pror'efining, hydrogenavention, the aluminum halide is combined with at least one halide of the group consisting of the halides of Li, Na, K, Rb, Cs, Be, Mg, Zn and Cd. These metals, it will be noted, are all members of the first and second groups of the Mendeljeff system of the elements and all form easily fusible halide salts of closely related properties. They all react with aluminum halides to form double halide salts of the type described. Since,-of the available aluminum" halides, aluminum chloride and least costly and most available, thesehalides I to be treated are removed prior to isomerization' by a suitable treatment component or components are for converting the are generally used as the aluminum halide components of'the melts. The alkaline metal halide also generally the It is not essential,

however, that t and aluminum 0 rrespond. Thus, I may use a suitable bromide and/or chloride in conjunction with aluminum bromide and/or chloride.

The ratio of aluminum halide to alkaline metal halide may vary within the scope of the invention in accordance with the particular characteristics chloride and/orlgromides.

of the catalyst desired, operating conditions, etc.

As explained above,,the aluminum halide must be used in molecular excess and is preferably used in mol ratio of 1.2 to 1, or greater. In general, mol ratios of aluminum halide above about 5 to 1' are not preferred since they require higher temperatures and consequently cause excessive degradation, especially when treating the less stable hydrocarbons. Particularly suitable cat-' alysts comprise the aluminum halide and other metal halides in preaching their eutectic mixtures. 7

These catalysts, which as shown above possess appreciable isomerization activity,

,In general, I prefer "to employ the lower halides of these metals, for example, their trichlorides.

The above described halides of metals of group V, hereinafter referred to as promoters, are used in the catalyst in minor proportions. Since they are in themselves inactive as catalysts, their use in more than necessary amounts serves onlylto dilute and reduce theactivity of the catalyst. In general, the optimum promoting effect is found to correspond to concentrations in the catalyst in the order of l-l5%. Amounts 25% and as low as 0.3%, however, usually give improved results ale may be employed.

As pointed out above; the promoting halides employed in the process of my invention are halides of metals of group V ofthe Mendeljeff system of the elements, which term is defined as including the semi-metallic element, arsenic. A very interesting fact to be pointed out is that halides of the purely non-metallic elements of this group are not only devoid of any promoting activity, but exert a decided negative, ,efiect upon the isorifieirizing activity of the- ,.fiuid aluminum in the following example.

, catalyst per se under aluminum bromide are the 4 Example Normal butane was isomerized under the conditions described in the foregoing examples using a base catalyst of the same composition to which was added 1% and 10% .by-weight of phosphorous trichloride (PClz). The conversions obtained were 6% and 2%, respectively. Since the base identical conditions gives the decided negative effect a conversion of 26%.

of even small amounts of PC13 is immediately apparent.

The isomerization when employing the abovehalides of the alkaline, metal the ratios of proportions, between the above limits, corresponding'to or apare promoted, and greatly improved by the incorporation of up to about employed inthe the liquid or vapor phase.

described fluid catalysts is preferably efiected in the presence of a hydrogen halide such as hydrogen chloride. This is preferably introduced into the reaqion zone with the hydrocarbon feed and, if desired, recovered from the product by halide. Inert materials such as pumice, coke, brick chips and the like, and gases such as C0, C02, N2, CH3, etc., appear to exert no deleterious efi'ect upon the activity of the'catalyst and may be present in the reaction zone. Water and hydrogen sulfide, however, are detrimental and are excluded as "far as practical.

The isomerization, according to the present process, may :be executed at peratures at which the catalyst may be maintained in a mobile liquid state depends upon the composition of the particular catalyst. By com- 130" C. and even lower.

Pressure appears to have little influence upon I the isomerization reaction. When eflecting the isomerization in the vapor phase pressures.rangpressure up to about ing from about atmospheric sired.

The described fliiid promoted catalyst may be process-of the invention for the isomerization of saturated hydrocarbons in either merization of butane using these promoted cata ized in the liquid phase.

The vapor phase iso-x The isomerlzation may be carried out either batchwise or continuously and with either concurrent or countercurrent flow oi the hydrocarbon and fluidcatalyst. Thus, the process may be efiected in simple apparatus of conventional type such as stirring autoclaves, packed towers, tubular reactors, and the like.

The process of my invention utilizing the described promoted vantages over hitherto-proposed isomerization processes. In my process, due to the excellent fluid catalysts has many ad-" contact obtained with the fluid catalyst and the ide of an alkali carbons which ide of an alkali greatly improved isomerizing' activity resulting from the use of activating amounts of the de-" scribed promoters, excellent and practical connum chloride are eliminated.

I claim as my invention:

l. A process for isomerizing saturated hydrocarbons which comprises contactingan isomer- 25% of antimony trichloride, whereby isomerization is effected as the primary reaction.

3. A process for isomerizing saturated hydrocarbons which comprises contacting-an isomerizable saturated hydrocarbon under isomerizing conditions with a fluid melt comprising a molecular excess of aluminum chloride and a halide of an alkali metal promoted by from 0.3% to 25% of bismuth trichloride, whereby isomerization is efi'ected as the primary reaction.

4. A process for isomerizing saturated'hydrocarbons-which comprises contacting an isomer izable saturated hydrocarbon'under isomerizing conditions with a fluid melt comprising a molecular excess of an aluminum ha! ae and a halmetal promoted by from 0.3% to 25% of a halide of arsenic, whereby isomerization is eflected as the primary reaction.

5. A process f or isomerizing saturated-hydrocomprises contacting an isomerizhydrocarbon under isomerizing a fluid melt. comprising a moable saturated conditions with lecular excess of metal 25% 'of a halide or ation is affected as the primary reaction.

6. A process for isomerizing saturated. hydrocarbons which comprises contacting an isomerizable saturated hydrocarbon under isomerizing conditionswith afluid melt comprising a molecular excess of an aluminum halide and a halide V 01' an alkali metal promoted byirom 0.3% to 25% of a'halide of bismuth, whereby isomerization is effected as the primary reaction.-

7. A process for isomerizing saturated hydrocarbons which comprises contacting an isomerizable saturated hydrocarbon under isomerizingconditions with a fluid melt comprising an alu-, minum halide; a halide of sodium and a halide of potassium in the weight ratio'of about 8:1:1 promoted by an activating amount of a halide of a metal selected from the metals of group V of the periodic table, whereby'isomerization is,

effected as the primary reaction.

8. A process-for isomerizing saturated hydrocarbons which comprises contacting an isomerizable saturated hydrocarbon under isomerizing conditions with a fluid melt comprising a molec-- ular excess of an aluminum halide, a halide of an aluminum halide and a hal- I promoted by from 0.3% to antimony, whereby isomeriz- 1 sodium and a halide of potassium promoted by an activating amount of a halide of a metal selected from the metals or group V of the periodic table, wherebyisomerization is effected as the primary reaction.

9. A process carbons izable saturated hydrocarbon under isomerizing conditions with a fluid melt comprisin a molecular excess of aluminum chloride an a halide of an alkali V of the periodic table, whereby isomerization is 10. A process for comprises contacting butane under condiions with a fluid melt comprising a molecular excess of an aluminum halide and a halide of an alkali metal promoted by an activating amount of a halide of a metal selected rrom the metals of group V of the periodic table, whereby isomerization is effected as the primary reaction.

1l. A process for isomerizing saturated hydrocarbons which comprises contacting a paraflin hydrocarbon having from four .to nine carbon atoms under isomerizing conditions with a fluid melt'fcomprising a molecular excess of an aluminum halide and a halide of an alkali metal promoted by an activating amount of a halide of a metal selected from the metals of group V of the periodic table, whereby isomerization is effected as the primary reaction.

saturated hydro- Y which comprises contacting an isomer-- metal promoted by an activating halide of a metal selected from the 12. A process for isomerizing saturated hydrocarbons which comprises contactma saturated hydrocarbon having atoms under isomerizin'g conditions from four to ninewcarhonnnhwg, n V

melt comprising a molecular excess of an aluminum halide and a halide of an alkali metal promoted by an activating a metal selected from the periodic table,

v 13. A process carbons wher by isomerization is iected as. the primary reaction.

amount of a halide of t e metals of group V of for isomerizing saturated hydrowhich comprises contacting a hydrocarbon fraction consisting essentially. of saturated hydrocarbons having from four to nine carbon atoms under isomerizing conditions with a fluid melt comprising a molecular excess of an aluminum halide and a halide of an alkali metal promoted by of a metal-selected from the metals of group V of the periodic table, efiected as the 14. A process whereby isomerization is primary reaction. for isomerizing saturated hydrocarbons which comprises contacting 81115011121- conditions with a isomerizing amoleca halide or an alkali metal promoted by an activating amount of a halide of metals of group V of the a metal selected irom the periodic table, whereby isomerization is effected as the primary reaction.

nann A. CHENEY. 

